U.S. patent application number 10/695227 was filed with the patent office on 2005-04-28 for fluid dispensing components.
Invention is credited to Hatton, Jason D., Hess, John M. III, Tuckey, Steven R..
Application Number | 20050087555 10/695227 |
Document ID | / |
Family ID | 34522744 |
Filed Date | 2005-04-28 |
United States Patent
Application |
20050087555 |
Kind Code |
A1 |
Hatton, Jason D. ; et
al. |
April 28, 2005 |
Fluid dispensing components
Abstract
Components are provided for use in systems for dispensing
fluids. A resilient diaphragm is provided for a diaphragm pump. The
diaphragm includes a pressurizing portion connected with a
connecting member to a peripheral mounting flange for mounting the
diaphragm in the housing of the pump. The pump housing has a
retention wall which can be swaged against the diaphragm flange.
The pump housing has a discharge structure with an outlet valve and
a restraint structure adjacent the valve to prevent in-venting
through the outlet valve. The outlet valve includes a flange which
is retained by a retention wall and which projects from the
discharge structure and which is swaged into engagement with the
outlet valve flange.
Inventors: |
Hatton, Jason D.;
(Essexville, MI) ; Tuckey, Steven R.; (Freeland,
MI) ; Hess, John M. III; (Midland, MI) |
Correspondence
Address: |
WOOD, PHILLIPS, KATZ, CLARK & MORTIMER
500 W. MADISON STREET
SUITE 3800
CHICAGO
IL
60661
US
|
Family ID: |
34522744 |
Appl. No.: |
10/695227 |
Filed: |
October 28, 2003 |
Current U.S.
Class: |
222/209 ;
222/494 |
Current CPC
Class: |
A47K 5/1208
20130101 |
Class at
Publication: |
222/209 ;
222/494 |
International
Class: |
B65D 037/00 |
Claims
1. A discharge structure for dispensing liquid from a supply of
said liquid, said structure comprising: a discharge conduit
defining a flow passage for establishing fluid communication with
said liquid from said supply of said liquid; a resilient,
pressure-actuatable valve that (1) extends across said discharge
conduit flow passage in an initial, substantially non-deformed,
closed configuration, (2) has an interior side for being contacted
by said liquid and an exterior side exposed to the ambient external
atmosphere, (3) has a head defining part of said interior side and
defining a normally self-sealing closed orifice, and (4) a sleeve
defining part of said interior side and extending from the
periphery of said valve head to accommodate movement of said valve
head outwardly to an open configuration when the pressure on a
portion of said valve interior side exceeds the pressure on said
valve exterior side by a predetermined amount; and a restraint
structure disposed in said discharge conduit in contact with said
valve interior side at said valve head when said valve is in said
initial, substantially non-deformed, closed configuration, said
restraint structure and said discharge conduit together defining at
least one flow path for initially accommodating flow of said liquid
from said supply against a portion of said valve interior side at
said valve sleeve laterally beyond said valve head, said restraint
structure preventing said closed orifice from opening inwardly when
the ambient external pressure on the valve exterior side exceeds
the pressure on the valve interior side.
2. The discharge structure in accordance with claim 1 in which said
interior side of said valve head includes a central flat surface
and a peripheral curved surface; said orifice is defined by slits
through said valve head which extend laterally from said valve head
central flat surface into said valve head peripheral curved
surface; and said restraint structure defines (1) an imperforate,
central, flat engaging surface for matingly engaging said valve
head central flat surface, and (2) an imperforate, peripheral
curved surface for matingly engaging said valve head peripheral
curved surface from said valve head flat surface to a location that
is at least laterally beyond said slits.
3. The discharge structure in accordance with claim 1 in which said
discharge conduit includes an annular wall merging with the
periphery of said restraint structure via a plurality of connecting
legs to define a plurality of flow passages accommodating flow
against said valve interior side at said valve sleeve laterally
beyond said valve head.
4. The discharge structure in accordance with claim 1 in which said
discharge conduit is part of a pump having a pressurizable
reservoir for containing a supply of said liquid.
5. A peripheral mounting flange for a resilient,
pressure-actuatable valve that can discharge a fluid product in an
outward flow direction and that has a head defining a normally
self-sealing closed dispensing orifice and having a sleeve
extending from the periphery of said head, said peripheral mounting
flange being adapted for being retained by a retention wall that is
inelastically deformed against said peripheral mounting flange,
said peripheral mounting flange comprising: resilient material
extending from the periphery of said sleeve in a generally annular
configuration about a longitudinal axis that extends axially
inwardly and axially outwardly relative to said flow direction,
said generally annular configuration being located around and
radially outwardly of said longitudinal axis, said resilient
material having a surface region defined at least in part by the
following surfaces: a first surface extending generally axially
outwardly from said sleeve; a second surface extending generally
axially inwardly from said sleeve; a third surface extending both
generally axially outwardly and radially outwardly from said first
surface; and a fourth surface extending both generally axially
inwardly and radially outwardly from said second surface so that
the third and fourth surfaces generally diverge.
6. The valve peripheral mounting flange in accordance with claim 5
further including: a fifth surface extending both generally axially
inwardly and radially outwardly from said third surface.
7. The valve peripheral mounting flange in accordance with claim 6
further including: a sixth surface extending both generally axially
outwardly and radially outwardly from said fourth surface.
8. The valve peripheral mounting flange in accordance with claim 7
further including: a seventh surface extending generally axially
outwardly from said sixth surface; and an eighth surface extending
generally axially inwardly from said seventh surface.
9. The valve peripheral mounting flange in accordance with claim 8
further including: a ninth surface extending generally axially
outwardly from said eighth surface; and a tenth surface extending
generally radially inwardly from said ninth surface.
10. A diaphragm pump comprising: (A) a diaphragm of resilient
material molded to define (1) a resiliently deformable,
pressurizing portion that (a) has an undeformed convex
configuration as viewed from the exterior, and (b) defines a
concave receiving region as viewed from the interior for
pressurizing fluid; (2) a connecting member extending from the
periphery of said pressurizing portion; and (3) a mounting flange
that (a) extends generally radially from the periphery of said
connecting member, (b) is thicker than said connecting member, (c)
has a first surface extending outwardly from said connecting member
in the direction toward the exterior, and (d) has a second surface
extending inwardly from said connecting member in the direction
away from the exterior; and B. a pump housing defining an inlet and
outlet and further including a retention structure for retaining
said diaphragm mounting flange, said retention structure including
a projecting wall that has a lateral surface and an end surface,
said wall end surface being spaced from said diaphragm connecting
member when said pump is not pressurizing said fluid, said wall
lateral surface being spaced from said diaphragm mounting flange
second surface when said pump is not pressurizing said fluid
whereby assembly of said diaphragm into said pump housing is
facilitated.
11. The pump in accordance with claim 10 in which said mounting
flange second surface defines a substantially interior cylindrical
surface.
12. The pump in accordance with claim 10 in which said connecting
member is arcuate.
13. The pump in accordance with claim 10 in which said connecting
member defines a convex surface projecting toward, but not
engaging, said retention structure projecting wall end surface.
14. The pump in accordance with claim 10 in which at least a
portion of said retention structure projecting wall lateral surface
is engageable by a portion of said mounting flange when said pump
is pressurizing said fluid.
15. A diaphragm for a pump, said diaphragm comprising: a resilient
material molded to define (A) a resiliently deformable,
pressurizing portion that (1) includes an undeformed convex
configuration when viewed from the exterior, and (2) defines a
receiving region under said convex configuration for receiving
fluid that can be pressurized by deforming said pressurized
portion; (B) a stress isolation connecting member extending from
the periphery of said pressurizing portion, said stress isolation
connecting member having a non-linear cross-sectional
configuration; and (C) a mounting flange that (1) extends from the
periphery of said stress isolation connecting member, and (2) can
be disposed in a retention structure of said pump.
16. The diaphragm in accordance with claim 15 in which said
diaphragm includes an annular base wall around the bottom of said
pressurizing portion; and in which said stress isolation connecting
member has an arcuate cross section and connects said annular base
wall with said mounting flange.
17. The diaphragm in accordance with claim 16 in which said arcuate
cross section is of uniform thickness over at least a major portion
of its radial length.
18. The diaphragm in accordance with claim 17 in which said arcuate
cross section defines a concave annular channel around said
pressurizing portion as viewed from the exterior.
19. A diaphragm for a pump having a retention structure that
includes an inelastically deformable exterior retention wall, said
diaphragm comprising: a resilient material molded to define (A) a
resiliently deformable, pressurizing portion that (1) has an
undeformed convex configuration as viewed from the exterior, and
(2) defines a concave receiving region as viewed from the interior
for pressurizing fluid; and (B) a mounting flange that (1) is
connected with the periphery of said pressurizing portion, (2) can
be disposed in said pump so that said exterior retention wall can
be inelastically deformed against said mounting flange, and (3) has
a generally annular configuration of resilient material extending
from the periphery of said sleeve wherein said material having a
surface region defined in part by the following surfaces: (a) inner
and outer diverging surfaces wherein said inner diverging surface
is inwardly of the location of the connection of said flange to
said pressurizing portion and wherein said outer diverging surface
is outwardly of the location of the connection of said flange to
said pressurizing portion; (b) a first corner surface extending
from said outer diverging surface; (c) a laterally extending
surface extending from said first corner surface; and (d) a second
corner surface extending from said laterally extending surface.
20. The diaphragm pump in accordance with claim 19 in which said
surface region of said generally annular configuration of resilient
material further includes a laterally peripheral surface that has
an outer margin and an inner margin wherein said outer margin is
located laterally further from said pressurizing portion than is
said inner margin.
Description
CROSS REFERENCE TO RELATED APPLICATION(S)
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO A MICROFICHE APPENDIX
[0003] Not applicable.
TECHNICAL FIELD
[0004] The present invention relates to components for dispensing
fluid, such as liquid. The components are particularly well suited
for use in a diaphragm pump for dispensing liquid, such as hand
soap.
BACKGROUND OF THE INVENTION AND TECHNICAL PROBLEMS POSED BY THE
PRIOR ART
[0005] There are a variety of components in use in various fluid
dispensing systems. Fluid dispensing systems typically include a
reservoir for fluid and a discharge structure which may be
connected to the fluid reservoir directly or through a conduit.
[0006] One type of conventional fluid reservoir is a pressurizable
cavity in a fluid dispensing pump which has a resiliently
deformable diaphragm that defines a convex wall of the cavity into
which fluid enters through a one-way inlet structure and from which
fluid is discharged through an outlet discharge structure. Such a
diaphragm is typically pushed inwardly to pressurize a fluid in the
cavity and squeeze the fluid out of the cavity through the
discharge structure of the pump. Such a diaphragm is typically
mounted in the housing of the pump. The periphery of the diaphragm
must be suitably retained by the pump housing to make a fluid-tight
seal that will not fail when the maximum design force or pressure
is applied to the diaphragm.
[0007] It would be desirable to provide an improved pump that
readily facilitates relatively rapid and correct assembly of the
diaphragm into the pump housing with a reduced number of separate
parts and that also provides a retention system that is sufficient
to maintain a fluid-tight seal between the housing and diaphragm
when the pump diaphragm is subjected to its maximum design force or
pressure.
[0008] Further, it would be beneficial to provide an improved
design of the diaphragm per se which would readily accommodate
proper placement of the diaphragm in the pump housing and which
would withstand the installation and retention forces so as to
reduce stress applied to the diaphragm.
[0009] It would also be advantageous to provide an improved
discharge structure for a fluid dispensing system, including a
fluid discharge structure that could be employed in, among other
devices, a fluid dispensing container or fluid dispensing pump.
Such an improved fluid discharge structure should advantageously
include a one-way discharge valve system that (1) prevents
in-venting of ambient atmosphere into the system, and (2) minimizes
hydraulic hammer pressure or water hammer in the system on the
outlet valve 38.
[0010] Further, it would be desirable if a discharge structure
could be provided with a discharge valve having an improved design
that readily accommodates mounting of the valve to one or more
discharge structure components in a way that, inter alia,
establishes a fluid-tight seal, reduces the number of separate
parts, and provides retention forces sufficient to properly retain
the valve.
[0011] Improved dispensing system components should also desirably
withstand rugged handling or abuse without leaking.
[0012] Further, it would be desirable if such improved system
components could accommodate efficient, high-quality, large volume
manufacturing techniques with a reduced product reject rate.
[0013] The present invention provides improved dispensing system
components which can accommodate designs having the above-discussed
benefits and features.
BRIEF SUMMARY OF THE INVENTION
[0014] The present invention provides improved components which can
be employed in a fluid dispensing system. One aspect of the
invention is a discharge structure for dispensing liquid from a
supply of liquid. The discharge structure includes a discharge
conduit defining a flow passage for establishing fluid
communication with the liquid from the supply of liquid. The
discharge structure includes a resilient valve that (1) extends
across the discharge conduit flow passage in an initial,
substantially non-deformed, closed configuration, (2) has an
interior side for being contacted by the liquid and an exterior
side exposed to the ambient external atmosphere, (3) has a head
defining part of the interior side and defining a normally
self-sealing closed orifice, and (4) a sleeve defining part of the
interior side and extending from the periphery of the valve head to
accommodate movement of the valve head outwardly to an open
configuration when the pressure on a portion of the valve interior
side exceeds the pressure on the valve exterior side by a
predetermined amount. The discharge structure also includes a
restraint structure disposed in the discharge conduit in contact
with the valve interior side at the valve head when the valve is in
the initial, substantially non-deformed, closed configuration. The
restraint structure and the discharge conduit together defining at
least one flow path for initially accommodating flow of the liquid
from the supply against a portion of the valve interior side at the
valve sleeve laterally beyond the valve head. The restraint
structure prevents the closed orifice from opening inwardly when
the ambient external pressure on the valve exterior side exceeds
the pressure on the valve interior side. The restraint structure
can also minimize the effects of hydraulic water hammer pressure on
the outlet valve 38 when the diaphragm dome 52 is subjected to a
high, rapidly applied actuating force.
[0015] Another aspect of the invention relates to a peripheral
mounting flange of a resilient, pressure-actuatable valve that can
discharge a fluid product in an outward flow direction and that has
(1) a head defining a normally self-sealing closed dispensing
orifice, and (2) a sleeve extending from the periphery of the head.
The peripheral mounting flange is adapted for being retained by a
retention wall of a valve holding structure wherein the retention
wall is deformed against the peripheral mounting flange. The
peripheral mounting flange includes a resilient material extending
from the periphery of the sleeve in a generally annular
configuration about a longitudinal axis that extends axially
inwardly and axially outwardly relative to the flow direction. The
generally annular configuration of material is located around and
radially outwardly of the longitudinal axis. The resilient material
has a surface region defined at least in part by the following
surfaces as viewed in cross section:
[0016] a first surface extending generally axially outwardly from
the sleeve; and
[0017] a second surface extending generally axially inwardly from
the sleeve.
[0018] In a preferred embodiment, the flange also includes one or
more of the following surfaces:
[0019] a third surface extending both generally axially outwardly
and radially outwardly from the first surface;
[0020] a fourth surface extending both generally axially inwardly
and radially outwardly from the second surface so that the third
and fourth surfaces generally diverge;
[0021] a fifth surface extending from the third surface both
generally axially inwardly and radially outwardly; and
[0022] a sixth surface extending from the fourth surface both
generally axially outwardly and radially outwardly.
[0023] Another aspect of the invention relates to an improved
diaphragm pump. The pump includes a diaphragm of resilient material
molded to define a resiliently deformable pressurizing portion, a
connecting member, and a mounting flange. The resiliently
deformable, pressurizing portion includes an undeformed convex
configuration as viewed from the exterior, and defines a concave
receiving region as viewed from the interior for pressurizing
fluid. The connecting member extends from the periphery of the
pressurizing portion. The mounting flange (a) extends generally
radially from the periphery of the connecting member, (b) is
thicker than the connecting member, (c) has a first surface
extending outwardly from the connecting member in the direction
toward the exterior, and (d) has a second surface extending
inwardly from the connecting member in the direction away from the
exterior.
[0024] The improved pump further includes a pump housing defining
an inlet and outlet. The pump housing includes a retention
structure for retaining the diaphragm mounting flange. The
retention structure includes a projecting wall that has a lateral
surface and an end surface. When the pump is not pressurizing the
fluid, the wall end surface is spaced from the diaphragm connecting
member, and the wall lateral surface is spaced from the diaphragm
mounting flange second surface. This arrangement facilitates
assembly of the diaphragm into the pump housing.
[0025] Another aspect of the invention provides in improved
diaphragm for a pump. The diaphragm is molded from a resilient
material to define at least the following three features:
[0026] (A) a resiliently deformable, pressurizing portion that (1)
has an undeformed convex configuration when viewed from the
exterior, and (2) defines a receiving region under the convex
configuration for receiving fluid that can be pressurized by
deforming the pressurized portion;
[0027] (B) a stress isolation connecting member that (1) extends
from the periphery of the pressurizing portion, and (2) has a
non-linear cross-sectional configuration; and
[0028] (C) a mounting flange that (1) extends from the periphery of
the stress isolation connecting member, and (2) can be disposed in
a retention structure of the pump.
[0029] Yet another aspect of the invention also provides an
improved diaphragm for a pump wherein the pump has a retention
structure that includes an inelastically deformable exterior
retention wall. The diaphragm includes a resilient material molded
to define at least the following:
[0030] (A) a resiliently deformable, pressurizing portion that (1)
has an undeformed convex configuration as viewed from the exterior,
and (2) defines a concave receiving region as viewed from the
interior for pressurizing fluid; and
[0031] (B) a mounting flange that (1) is connected with the
periphery of the pressurizing portion, (2) can be disposed in the
pump so that the exterior retention wall can be inelastically
deformed against the mounting flange, and (3) has a generally
annular configuration of resilient material extending from the
periphery of the sleeve wherein the material has a surface region
defined in part by the following surfaces:
[0032] (a) inner and outer diverging surfaces wherein the inner
diverging surface is inwardly of the location of the connection of
the flange to the pressurizing portion and wherein the outer
diverging surface is outwardly of the location of the connection of
the flange to the pressurizing portion;
[0033] (b) a first corner surface extending from the outer
diverging surface;
[0034] (c) a laterally extending surface extending from the first
corner surface; and
[0035] (d) a second corner surface extending from the laterally
extending surface.
[0036] Numerous other advantages and features of the present
invention will become readily apparent from the following detailed
description of the invention, from the claims, and from the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0037] In the accompanying drawings that form part of the
specification, and in which like numerals are employed to designate
like parts throughout the same,
[0038] FIG. 1 is a perspective view of a dispensing system
comprising a plurality of components assembled to form a diaphragm
pump for dispensing a liquid, and the pump is viewed from the
actuation side of the pump from which the pump diaphragm
projects;
[0039] FIG. 2 is a view of the reverse side of pump illustrated in
FIG. 1;
[0040] FIG. 3 is an exploded, perspective view from the actuation
side of the pump illustrated in FIG. 1 wherein the pump housing is
shown in an as-molded condition with an upstanding retention wall
prior to the diaphragm being inserted into the pump housing and
prior to the retention wall being inelastically deformed over the
flange of the diaphragm, and wherein the discharge structure outlet
spout is shown in an as-molded condition with a projecting
retention wall prior to the outlet valve being disposed in the
spout and prior to the retention wall being inelastically deformed
over the flange of the valve;
[0041] FIG. 4 is an exploded perspective view from the reverse side
of the pump components illustrated in FIG. 2 wherein the components
are shown in the as-molded condition prior to assembly;
[0042] FIG. 5 is a plan view from the actuation side of the fully
assembled pump illustrated in FIG. 1;
[0043] FIG. 6 is a side elevational view of the fully assembled
pump illustrated in FIG. 1;
[0044] FIG. 7 is a plan view of the reverse side of the pump shown
in FIG. 5;
[0045] FIG. 8 is a bottom end view of the pump illustrated in FIG.
1;
[0046] FIG. 9 is a cross-sectional view taken generally along the
plane 9-9 in FIG. 8;
[0047] FIG. 10 is a greatly enlarged, fragmentary view of the
portion of the pump shown in FIG. 9 wherein the pump diaphragm
flange is retained by an inelastically deformed wall of the pump
housing;
[0048] FIG. 11 is a greatly enlarged, exploded, perspective view of
the discharge spout assembly or discharge structure assembly of the
pump shown in FIG. 3 with the components in the as-molded,
unassembled condition;
[0049] FIG. 12 is an exploded, perspective view of the discharge
spout assembly illustrated in FIG. 11, but in FIG. 12, the
components of the assembly are viewed from the bottom;
[0050] FIG. 13 is a plan view of the exterior side of the outlet
valve illustrated in FIGS. 11 and 12;
[0051] FIG. 14 is a cross-sectional view taken generally along the
plane 14-14 in FIG. 13;
[0052] FIG. 15 is a greatly enlarged, fragmentary, cross-sectional
view of the end of the pump discharge structure illustrated in FIG.
9 which is taken generally along the plane 9-9 in FIG. 8;
[0053] FIG. 16 is a view similar to FIG. 15, but FIG. 16 is taken
along the plane 16-16 in FIG. 8;
[0054] FIG. 17 is a cross-sectional view taken generally along the
plane 17-17 in FIG. 16;
[0055] FIG. 18 is a view similar to FIG. 1, but FIG. 18 shows the
pump actuated to discharge or dispense liquid from the discharge
end of the pump;
[0056] FIG. 19 is a cross-sectional view similar to FIG. 9, but the
diaphragm is shown as being actuated or pushed in as in FIG. 18 so
as to dispense liquid from the pump through the open outlet
valve;
[0057] FIG. 20 is a greatly enlarged view of the outlet end or
discharge end of the pump taken generally along the plane 16-16 in
FIG. 8 with the pump being actuated as shown in FIG. 19; and
[0058] FIG. 21 is a view similar to FIG. 19, but FIG. 21 shows the
pump after the pushing force on the diaphragm has been released,
after the outlet valve has closed, and after the diaphragm inlet
valve has opened to permit liquid to flow into the diaphragm
pressurizing cavity to refill the pump.
DETAILED DESCRIPTION
[0059] While this invention is susceptible of embodiment in many
different forms, this specification and the accompanying drawings
disclose only specific forms of various aspects of the invention.
The invention is not intended to be limited to the embodiments so
described, however. The scope of the invention is pointed out in
the appended claims.
[0060] For ease of description, the components and assemblies of
this invention are described in an upright position, and terms such
as upper, lower, horizontal, etc., are used with reference to this
position. It will be understood, however, that the components and
assemblies of this invention may be manufactured, stored,
transported, used, and sold in an orientation other than the
upright position described herein.
[0061] The components of this invention may be employed in various
fluid dispensing systems, particularly liquid dispensing systems.
Various components of the present invention are particularly
well-suited for use in a discharge structure which may be connected
to a fluid supply directly or through a conduit. The components of
the present invention are especially useful in a fluid dispensing
pump which contains a fluid reservoir in the form of a
pressurizable cavity having an inlet and an outlet. Aspects of the
invention are especially suitable for use with a diaphragm type
dispensing pump which has a resiliently deformable diaphragm that
defines a convex wall of the cavity into which fluid enters though
a one-way valve inlet structure and from which fluid is discharged
through an outlet discharge structure. Such a diaphragm is
typically pushed inwardly to pressurize the fluid in the cavity and
to squeeze the fluid out of the cavity through the discharge
structure.
[0062] The fluid dispensing components of the present invention are
particularly well suited for use in a diaphragm pump, and one
presently preferred form of a diaphragm pump is illustrated in
FIGS. 1-21. The pump is designated generally in many of those
figures with the reference number 30. The pump 30 is especially
suitable for use in a wall-mounted dispenser for soap, lotion, and
hand care products.
[0063] In general, the operational aspects of the pump 30 are
somewhat similar to those of the pump illustrated in the U.S. Pat.
No. 6,216,916. The U.S. Pat. No. 6,216,916 illustrates a
wall-mounted dispenser 10 in which is incorporated a pump
comprising various major components, including a flexible diaphragm
or dome 60 defining a pressurizing chamber 90, an inlet connection
52, and an outlet connection or spout 200.
[0064] In accordance with the teachings of the instant invention
described herein, the pump 30 may be incorporated into a dispenser,
like the dispenser 10 shown in U.S. Pat. No. 6,216,916, in an
analogous manner to the above-described pump system disclosed in
the U.S. Pat. No. 6,216,916.
[0065] The pump 30 illustrated in FIGS. 1-21 in the instant patent
application may also be used in other suitable dispensers or other,
different fluid dispensing systems. Further, some of the individual
components or subassemblies of the pump 30 may, in accordance with
the teachings of various aspects of the present invention, be
incorporated in other types of fluid dispensing systems that do not
contain a pump.
[0066] As can be seen in FIG. 4, the pump 30 employs an improved
design that includes only four separate pieces: (1) a generally
rigid pump body 32, (2) a resiliently deformable, pressurizing dome
or diaphragm 34, (3) an outlet spout or conduit 36, and (4) a
dispensing valve, discharge valve, or outlet valve 38. Together,
the spout or discharge conduit 36 and valve 38 may be characterized
as a discharge structure or discharge subassembly of the pump
30.
[0067] The pump body or housing 32 includes a fluid inlet structure
or conduit 42. The conduit 42 accommodates flow of a liquid from a
suitable supply of liquid into the pump. For example, the conduit
42 could be connected to a collapsible bag (not illustrated) that
contains liquid soap.
[0068] The pump body or housing 32 also includes a hollow boss 44
defining a an internal outlet passage communicating with the spout
or discharge structure 36. The discharge structure 36 is designed
to be assembled with a snap-fit engagement to the end of the boss
44 as shown in FIG. 9. To this end, the inlet end of the spout 36
includes an annular channel 48 for snap-fit engagement with an
annular bead 50 on the pump housing boss 44 as shown in FIG. 9. The
two parts are designed to be matingly engaged to form a fluid-tight
connection. The particular detailed design of the snap-fit
engagement and of the internal mating configuration may be of any
suitable conventional or special design.
[0069] There is also a second engagement between the two parts
defined by a taper fit on the distal end of pump housing boss 44
and a taper fit at the mating portion of the spout 36 as can be
seen in FIG. 9.
[0070] Both the pump housing 32 and the mating spout 36 (but not
the outlet valve 38 and diaphragm 34) are preferably molded from a
homopolymer of polypropylene.
[0071] The diaphragm or membrane 34 is generally dome-shaped and
has a central convex configuration or dome 52 (FIGS. 8 and 9) as
viewed from the exterior of the pump. The diaphragm 34 defines a
concave cavity or reservoir on the inside that functions, in
cooperation with the pump housing 32, to hold the liquid which
flows into the pump through the inlet conduit 42. The dome 52 can
be deformed inwardly to pressurize the liquid. The dome 52 may be
characterized as a resiliently deformable pressurizing portion. It
need not have an arcuate, dome shape per se. It could have other
suitable configurations defining a pressurizable cavity.
[0072] The exterior side of the dome 52 includes a step or ridge 53
(FIGS. 6 and 9) which accommodates the use of configuration mold
parts that are more robust. The ridge is not needed for proper
functioning of the dome 52 per se.
[0073] The diaphragm 34 is preferably molded from a resilient
material which may be an elastomer, such as a synthetic
thermosetting polymer, including silicone rubber, such as the
silicone rubber sold by Dow Corning Corp. in the United States of
America under the trade designation D.C. 9280-70. Another suitable
silicone rubber product is sold by Wacker Silicone Company in the
United States of America, under the designation Wacker 3003-70
.ANG.. Both of these materials have a hardness rating of 70 Shore
A. The diaphragm 34 can also be molded from other thermosetting
materials or from other elastomeric materials, or from
thermoplastic polymers or thermoplastic elastomers, including those
based upon materials such as thermoplastic propylene, ethylene,
urethane, and styrene, including their halogenated
counterparts.
[0074] Owing to the unique configuration of the diaphragm 34, the
diaphragm 34 normally remains in the undeformed configuration shown
in FIGS. 1, 8, and 9, and this is a "self-maintained," unactuated
configuration. As shown in FIGS. 3, 4, and 9, the diaphragm 34
includes an annular base wall 54 around the bottom of the
pressurizing portion or dome 52. As shown in FIG. 9, the portion of
the annular base wall 54 that projects radially inwardly from the
dome 52 defines a resilient, flexible flap 56.
[0075] As can be seen in FIGS. 3, 9, and 10, the outer periphery of
the diaphragm base wall 54 terminates in, and merges with, an
annular connecting member 58. In the preferred embodiment, the
connecting member 58 performs a stress isolation function as is
described in detail hereinafter. The connecting member 58 connects
the diaphragm base wall 54 with a mounting flange 60. The mounting
flange 60 is adapted to be retained by the pump housing 32 (FIG. 9)
as described in detail hereinafter.
[0076] As can be seen in FIGS. 3 and 9, the pump housing 32 defines
an annular surface functioning as an inlet valve seat 64 at the
inner end of the inlet conduit 42. The inlet valve seat 64 is
adapted to be sealingly engaged by the inner surface of the
diaphragm base wall 54 when the pressure within the cavity of the
diaphragm 34 equals or exceeds the pressure of the liquid in the
conduit 42. If the pressure of the liquid in the conduit 42 exceeds
the pressure within the cavity of the diaphragm 34 by a sufficient
amount (as during the reduction of pressure in the cavity below the
pressure in the inlet conduit 42), then the resilient, flexible
flap 56 of the diaphragm base wall 54 is forced away from the valve
seat 64 as illustrated in FIG. 21, and this permits the fluid in
the inlet conduit 42 to flow into the cavity within the diaphragm
34 as shown in FIG. 21.
[0077] As can be seen in FIG. 3, the pump housing 32 is initially
molded from a suitable thermoplastic material so as to have a
configuration for receiving the diaphragm 34. To this end, the pump
housing 32 has an "as-molded" configuration wherein there is an
outwardly projecting, inelastically deformable, exterior, retention
wall 70. As can be seen in FIGS. 3 and 10, the pump housing 32 also
includes an annular inner projecting wall 72. The annular space
between the inner projecting wall 72 and the exterior retention
wall 70 functions as an annular receiving region for receiving and
holding the diaphragm mounting flange 60 when the diaphragm 34 is
installed in the pump housing 32.
[0078] After the diaphragm 34 is properly placed in the housing so
that the mounting flange 60 is disposed between the pump housing
inner projecting wall 72 and the exterior retention wall 70, the
exterior retention wall 70 is inelastically (i.e., plastically)
deformed into the configuration illustrated in FIGS. 9 and 10. When
the exterior retention wall 70 is in the "as-molded" outwardly
projecting orientation as shown in FIG. 3 prior to deformation of
the wall 70, the wall 70 can be heated and then deformed into the
configuration illustrated in FIG. 10. The heating may be effected
by any suitable process.
[0079] In one presently preferred process for heating and deforming
the wall 70, the wall 70 is deformed with an ultrasonic horn (not
illustrated) which heats the wall 70 by means of ultrasonic energy
and also forces the wall to deform into the configuration shown in
FIG. 10. This process is known as ultrasonic swaging.
[0080] The exterior curvature of the deformed wall 70 is
substantially defined by the shape of a concave forming surface in
the ultrasonic horn. The horn has a generally cylindrical end for
engaging the wall 70. The concave surface in the horn defines an
annular, downwardly open channel for receiving and engaging the
wall 70. The horn is connected in a conventional manner to a
conventional ultrasonic thruster assembly (not illustrated).
[0081] Ultrasonic deformation of a retention wall about a flange of
resilient material is described in detail in the U.S. Pat. No.
5,115,950, at columns 5 and 6 thereof. Ultrasonic deformation of a
wall about the flange of a resilient member is also described in
U.S. Pat. No. 6,273,307 with reference to FIG. 13 therein. The
description of the ultrasonic swaging process and apparatus
disclosed in the U.S. Pat. No. 5,115,950 is incorporated herein by
reference to the extent pertinent and to the extent not
inconsistent herewith.
[0082] Preferably, to ultrasonically deform the retention wall 70
to the configuration illustrated in FIG. 10 with an ultrasonic
swaging apparatus, the ultrasonic horn of the apparatus is moved
into engagement with the initially outwardly projecting wall 70 so
as to apply a force while actuating the ultrasonic system to apply
ultrasonic energy until one of the following two conditions first
occurs:
[0083] (1) the ultrasonic horn reaches a predetermined location
relative to the diaphragm flange 60 (i.e., a predetermined maximum
extension distance of the horn relative to the stationary part of
the ultrasonic apparatus); or
[0084] (2) the lapsing of 21/2 seconds.
[0085] In a presently preferred process, this results in the
application of a swaging force of about 680 pounds to the wall 70.
Then the ultrasonic energy is switched off, and the horn is
retracted. After the wall 70 has been properly deformed into the
configuration illustrated in FIG. 10, there is a very slight bit of
compression force on the diaphragm flange 60, but the compression
force is so slight that there is virtually no deformation of the
flange 60 as compared to the "as-molded" shape of the flange.
[0086] The pump housing 32 and the diaphragm flange 60 each have
configurations which facilitate relatively rapid and proper
mounting of the diaphragm 34 within the pump housing 32 and which
facilitate the subsequent deformation of the retention wall 70 so
as to provide a sufficiently strong retention engagement to prevent
diaphragm pull-out when the diaphragm is subjected to the maximum
design pressure. If the pump is used in a hand soap dispenser, such
as generally illustrated in the above-discussed U.S. Pat. No.
6,216,916, then a typical maximum design pressure for the internal
pump components, including the diaphragm, could be about 50 pounds
per square inch gauge.
[0087] As can be seen in FIG. 10, the pump housing 32 has a channel
defined between the inner wall 72 and the exterior wall 70. For
convenient reference, FIG. 10 illustrates four arrows: arrow 75,
arrow 77, arrow 79, and arrow 81. Arrow 75 illustrates the
generally axially outward direction relative to the diaphragm 34
and relative to the diaphragm flange 60. Arrow 77 represents the
generally axially inward direction relative to the diaphragm 34 and
its flange 60. Arrow 79 represents the generally radially outward
direction relative to the diaphragm and its flange 60. Arrow 81
represents the generally radially inward direction relative to the
diaphragm 34 and its flange 60.
[0088] In the following discussion and in the claims, the surfaces
of the channel and flange 60 are described with reference to the
cross section view taken radially through the channel and flange
(e.g., FIGS. 9 and 10).
[0089] The channel is defined at least in part by a first,
generally radial or vertical surface 82 and a second angled surface
84. The angled surface 84 may be characterized as extending both
(1) generally axially inwardly (in the direction of arrow 77 and
relative to the actuation side of the pump from which the diaphragm
dome projects), and (2) radially outwardly (in the direction of
arrow 79 and relative to the center of the diaphragm). At the lower
end of the angled surface 84 is an interior corner or curved
surface 86 which merges with a radially inwardly facing, slightly
curved or concave surface 87 on the inside of the retention wall
70. The surface 87 extends somewhat radially outwardly (relative to
the diaphragm and in the direction of arrow 79) from the corner 86
and extends from the curved corner surface 86 in a direction that
is generally axially outwardly (in the direction of arrow 75)
toward the actuation side of the pump from which the diaphragm
projects. The distal end portion of the pump housing retention wall
70 is deformed and bent over at the outer end of the surface
87.
[0090] The diaphragm flange 60 has a unique configuration to
facilitate its placement within the pump housing 32 and to
facilitate retention of the flange 60 in the housing 32. In
particular, the diaphragm flange 60 has a surface region defined by
the following surfaces shown in cross section FIG. 10:
[0091] (a) a generally straight, axially outwardly extending
surface 90 that extends outwardly (in the direction of arrow 79)
from the region where the connecting member 58 connects to the
flange 60;
[0092] (b) a generally straight, inwardly extending surface 92 that
extends axially inwardly (arrow 77) away from the region where the
connecting member 58 connects to the flange 60;
[0093] (c) an inner diverging surface 94 extending both radially
outwardly and axially inwardly from the surface 92, which is
generally straight, and which is axially inwardly of the location
of the connection of flange 60 to the connecting member 58;
[0094] (d) an outer diverging surface 96 which is generally
straight, which extends both radially outwardly and axially
outwardly from the surface 90, and which is axially outwardly of
the location of the connection of the flange 60 to the connecting
portion 58;
[0095] (e) a corner surface 98 extending from the outer diverging
surface 96;
[0096] (f) a laterally extending surface 100 which extends from the
first corner surface 98 and which extends laterally or radially
outwardly (arrow 79) relative to the diaphragm;
[0097] (g) a second corner surface 102 which extends from the
laterally extending surface 100; and
[0098] (h) a laterally peripheral surface 104 which extends from
the second corner surface 102.
[0099] The edge of the peripheral surface 104 adjacent the second
corner surface 102 may be defined as an outer margin that is
axially outwardly and radially outwardly relative to the rest of
the surface 104. The surface 104 extends from the second corner
surface 102 both axially inwardly and radially inwardly to an inner
margin that is connected via an exterior corner or curved surface
106 to the inner diverging surface 84. The edge of the peripheral
surface 104 at the corner 106 may be characterized as an inner
margin of the surface 104. Thus, the outer margin of the surface
104 along the second corner surface 102 is located laterally or
radially further outwardly (arrow 79) from the diaphragm
pressurizing portion (e.g. dome 52) than is the inner margin of the
peripheral surface 104 at the corner 106.
[0100] The pump housing 32 is configured to facilitate assembly of
the diaphragm 34 into the pump housing 32 and to facilitate receipt
of the diaphragm flange 60. To this end, it will be noted that the
pump housing inner wall 72 has a distal end 110 and a laterally
outwardly facing lateral surface 112. When the pump housing outer
retention wall 70 is properly deformed about the diaphragm flange
60 (FIG. 10), and when the pump is not being actuated to pressurize
the liquid within the pump, then the following conditions
preferably obtain:
[0101] (1) the diaphragm dome 52 and base wall 54 are not subjected
to significant deformation or excessive stress,
[0102] (2) the inner surface of the diaphragm connecting member 58
is spaced from the pump housing inner wall end surface 110 as shown
in FIG. 10, and
[0103] (3) the diaphragm flange inner surface 92 is spaced from the
pump housing inner wall lateral surface 112 as shown in FIG.
10.
[0104] The spacing between the lateral surface 112 and the
diaphragm flange surface 92 is especially desirable in
accommodating installation of the diaphragm flange 60 into its
proper location within the pump housing prior to deformation of the
pump housing exterior retention wall 70 into engagement with the
outer surface of the diaphragm flange 60.
[0105] When the pump is actuated, and especially if the actuation
creates a relatively high pressure adjacent the diaphragm 34, a
portion of the diaphragm flange wall 92 may engage the pump housing
inner wall lateral surface 112, especially near the pump housing
inner wall end surface 110. This engagement aids in preventing
pull-out of the diaphragm flange 60. This insures that the
diaphragm 34 will remain properly retained within the pump housing
32 and that a leak-tight sealing engagement will continue to exist
within the pump.
[0106] The space between the inner surface of the diaphragm
connecting member 58 and the pump housing inner wall end surface
110 permits the diaphragm 34 to be readily positioned in the pump
housing 32 prior to the exterior retention wall 70 being deformed
into engagement with the diaphragm flange 60. Further, the space
between the connecting member 58 and the end surface 110 of the
pump housing inner projecting wall 72 permits some amount of
movement or flexing of the connecting member 58 during the
following conditions:
[0107] (1) during placement of the diaphragm 34 within the pump
housing,
[0108] (2) during subsequent deformation of the pump housing
exterior retention wall 70 against the diaphragm flange 60, and
[0109] (3) during operation or actuation of the pump.
[0110] In some applications, especially applications where the pump
maximum design pressure is relatively low, the inner projecting
wall 72 may be omitted.
[0111] According to one aspect of the present invention, the
connecting member 58 preferably functions as stress isolation
feature. In the preferred form illustrated in FIG. 10, the
connecting member 58 has an arcuate cross section. Further, in the
most preferred form presently contemplated, the connecting member
58 has a uniform thickness over at least a major portion of its
radial length (i.e., the length of the connecting member generally
in the direction of the arrow 79 in FIG. 10). Further, the
presently most preferred form of the connecting member 58 defines a
concave annular channel around the diaphragm pressurizing portion
as viewed from the exterior of the pump. The connecting member may
be characterized, in its most preferred form illustrated in FIG.
10, as having a sideways oriented, generally U-shaped
configuration.
[0112] The novel stress isolation connecting member 58 serves to
isolate, or at least minimize the transfer of stress to, the
portion of the diaphragm 34 which is radially inwardly of the
diaphragm flange 60. This is especially important during the
process of deforming or swaging the pump housing exterior retention
flange 70 into engagement with the flange 60. It has been found
that the action of deforming the retention wall 70 into engagement
with the flange 60 can produce some amount of stress in the
resilient material of the diaphragm. The arcuate configuration of
the connecting member 58 has been found to be especially effective
in minimizing the transfer of such stress into the interior portion
of the diaphragm that extends radially inwardly from the connecting
member 58.
[0113] The various unique surfaces of the diaphragm flange 60
provide various advantages. In particular, the surface 94 (FIG.
10A) matches the geometry of the adjacent pump housing surface 84
so as to minimize the likelihood of the flange 60 from shifting
during assembly, and this also reduces the assembly effort relative
to designs that would have a more complicated geometry.
[0114] The flange surface 104, and the mating, somewhat arcuate
surface 87 of the pump housing outer retention wall 70 aid in the
ultrasonic deformation process by directing ultrasonic energy in a
way that improves the process of deforming the wall 70.
[0115] It can be seen in FIG. 10 that the inside surface 87 of the
wall 70 has a configuration which is laterally further from the
diaphragm dome (in the direction of the arrow 79 in FIG. 10) with
increasing distance along the wall 70 from the bottom of the wall
(at the corner 86) to the free end of the wall 70 which is deformed
over and against the diaphragm flange 60. The shape of the
retention wall inside surface 87 contributes to an overall tapering
or thinning of the base portion of the wall and facilitates the
deformation of the outer portion of the wall 70 in the desired,
deformed configuration.
[0116] The diaphragm flange corner surface 102 is preferably
rounded as illustrated in FIG. 10 but may also be generally
straight and angled. The surface 102 matches the geometry in that
region of the diaphragm flange 60 to the inside surface geometry of
the deformed retention wall 70 so as to enhance the retention of
the diaphragm flange 60 and enhance the capability of the assembly
to withstand the pull-out forces generated by the pressurization of
the pump during the operation of the pump.
[0117] The diaphragm flange surface 100 is preferably generally
straight, but also may be slightly curved. The surface 100 permits
that region of the diaphragm flange 60 to match the geometry of the
adjacent inner surface of the retention wall 70 to enhance
retention of the diaphragm flange and to enhance the capability of
the assembly to withstand pull-out forces generated by
pressurization of the pump.
[0118] The diaphragm flange surface 98 is preferably slightly
curved, but also may be straight. The surface 98 permits that
region of the diaphragm flange 60 to match the geometry of the
adjacent inner surface of the retention wall 70 to enhance
retention of the diaphragm flange and to enhance the capability of
the assembly to withstand pull-out forces generated by
pressurization of the pump.
[0119] The diaphragm flange surface 96 is preferably generally
straight, but also may be slightly curved. The surface 96 permits
that region of the diaphragm flange 60 to match the geometry of the
adjacent inner surface of the retention wall 70 to enhance
retention of the diaphragm flange and to enhance the capability of
the assembly to withstand pull-out forces generated by
pressurization of the pump.
[0120] The novel discharge structure of the pump provides
operational advantages as discussed hereinafter. The discharge
structure may be characterized as including the assembly of the
discharge conduit or spout 36 and the resilient,
pressure-actuatable, outlet valve 38 as shown in FIGS. 9, 11, and
12. The discharge structure components (i.e., the spout 36 and
valve 38) may be employed in dispensing systems other than a pump
30.
[0121] FIGS. 11 and 12 illustrate the discharge conduit or spout 36
in the "as-molded" configuration prior to deformation of the distal
end of the spout 36 about the valve 38. As described hereinafter,
the valve 38 is preferably provided with a unique flange structure
to accommodate deformation of the distal end of the discharge
conduit or spout 36 in a way that facilitates assembly and proper
retention of the valve after deformation of the distal end portion
of the spout 36. The valve flange also accommodates the
establishment of a retention configuration that enhances the
resistance against valve pull-out and that enhances the fluid-tight
engagement between the valve 38 and the spout 36.
[0122] As illustrated in FIG. 12, the "as-molded" configuration of
the discharge conduit or spout 36 has an outwardly projecting,
inelastically deformable retention wall 120 for accommodating
initial placement of the valve 38 in the end of the spout 36.
Subsequently, the distal end portion of the retention wall 120 is
swaged by inelastically deforming the wall over a peripheral
portion of the valve 38 as described hereinafter.
[0123] As illustrated in FIG. 12, the discharge conduit or spout 36
includes an inwardly recessed restraint structure for restraining
movement of the valve 38 inwardly under certain conditions of
operation as described hereinafter. As illustrated in FIGS. 12 and
20, the restraint structure defines (1) an imperforate, central,
flat engaging surface 130, and (2) an imperforate, peripheral
curved surface 132.
[0124] As can be seen in FIG. 20, the discharge conduit or spout 36
includes an annular wall 136, and a plurality of legs 138 connect
the annular wall 136 with the restraint structure peripheral curved
surface 132. A plurality of flow passages 140 are defined between
the connecting legs 138. As can be seen in FIGS. 12 and 20,
outwardly facing surface of each of the legs 138 is slightly angled
or curved outwardly. With reference to FIG. 20, the flat surface
130, the curved surface 132, the legs 138, and the annular wall 136
together define the restraint structure for restraining the valve
38 against inward deformation or movement when the valve is
properly installed and in the closed condition as shown in FIG.
16.
[0125] The discharge valve, dispensing valve, or outlet valve 38 is
separately illustrated in FIGS. 13 and 14. In a presently preferred
form, the valve is a "pressure-openable" valve which opens when a
sufficient pressure differential is applied across the valve (e.g.,
as by increasing the pressure on one side and/or decreasing the
pressure on the other side).
[0126] In the presently preferred form of the valve 38 illustrated
in FIGS. 13 and 14, the valve 38 is molded as a unitary structure
from material which is flexible, pliable, elastic, and resilient.
This can include elastomers, such as a synthetic, thermosetting
polymer, including silicone rubber, such as a silicone rubber sold
by Dow Corning Corp. in the United States of America under the
trade designation D.C. 99-595-HC. Another suitable silicone rubber
material is sold in the United States of America under the
designation Wacker 3003-40 by Wacker Silicone Company. Both of
these materials have a hardness rating of 40 Shore A. The valve 38
could also be molded from other thermosetting materials or from
other elastomeric materials, or from thermoplastic polymers or
thermoplastic elastomers, including those based upon materials such
as thermoplastic propylene, ethylene, urethane, and styrene,
including their halogenated counterparts.
[0127] The design configuration of valve 38, and the operating
characteristics thereof, are substantially similar to the
configuration and operating characteristics of the valve designated
by the reference number 3d in the U.S. Pat. No. 5,409,144. The
description in that patent is incorporated herein by reference to
the extent pertinent and to the extent not inconsistent
herewith.
[0128] As illustrated in FIGS. 13 and 14 herein, the valve 38
includes a head or head portion 150 which is flexible and which has
an outwardly concave configuration (as viewed from the exterior of
the valve 38 when the valve 38 is mounted in the spout 36). The
head 150 defines at least one, and preferably two, dispensing slits
152 extending through the head 150 to define a normally
self-sealing closed orifice. The preferred form of the valve 38 has
two, mutually perpendicular, intersecting slits 152 of equal
length. The intersecting slits 152 define four, generally
sector-shaped, flaps or petals in the head 150. The flaps open
outwardly from the intersection point of the slits 152 in response
to an increasing pressure differential of sufficient magnitude in
the well-known manner described in the above-discussed U.S. Pat.
No. 5,409,144.
[0129] The valve 38 has an interior side for facing generally into
the spout 36 and an exterior side for facing generally outwardly
from the spout 36. The interior side of the valve 38 is adapted to
be contacted by the liquid, and the exterior side of the valve 38
is exposed to the ambient external atmosphere.
[0130] The valve 38 includes a thin skirt 154 which extends axially
and radially outwardly from the valve head 150. The outer end
portion of the skirt 154 terminates in an enlarged, much thicker,
peripheral flange 160 which has a generally dovetail shaped
transverse cross section.
[0131] With reference to FIG. 14, the interior side of the valve
head 150 includes a circular, central, flat surface 164 and a
peripheral, curved surface 166 around the central flat surface 164.
The slits 152 extend laterally from the valve head central, flat
surface 164 into the valve head peripheral, curved surface 166.
[0132] When the valve 38 is properly disposed in the discharge
conduit 36 (FIGS. 9, 15, 16, 20, and 21) with the valve head 150 in
the closed condition, the valve 38 is recessed relative to the end
of the spout 36. However, when the head 150 is forced outwardly
from its recessed position by pressurized liquid, the valve opens
as shown in FIGS. 19 and 20. More specifically, when the pressure
on the interior side of the valve 38 exceeds the external ambient
pressure by a predetermined amount, the valve 38 is forced
outwardly from the recessed or retracted position to an extended,
open position as shown in FIGS. 18, 19, and 20.
[0133] During the valve opening process, the valve head 150 is
initially displaced outwardly while still maintaining its generally
concave, closed configuration. The initial outward displacement of
the concave head 150 is accommodated by the relatively, thin,
flexible, skirt 154. The skirt 154 moves from a recessed, rest
position to the pressurized position wherein the skirt 154 extends
outwardly toward the open end of the spout 36. However, the valve
38 does not open (i.e., the slits 152 do not open) until the valve
head 150 has moved substantially all the way to a fully extended
position. Indeed, as the valve head 150 moves outwardly, the valve
head 150 is subjected to radially inwardly directed compression
forces which tend to further resist opening of the slits 152.
Further, the valve head 150 generally retains its outwardly concave
configuration as it moves forward and even after the sleeve 154
reaches the fully extended position. However, when the internal
pressure becomes sufficiently great compared to the external
pressure, then the slits 152 in the extended valve head 150 open to
dispense product.
[0134] As can be seen in FIG. 16, the discharge spout 36 defines an
annular valve seat 170 for receiving and engaging a portion of the
valve flange 160 when the valve 38 is properly disposed within the
distal end of the spout 36. When the valve 38 is properly disposed
within the spout 36 as shown in FIG. 16, the valve head interior,
central, flat surface 164 is seated against the spout mating,
central, flat surface 130. Similarly, the peripheral curved surface
166 of the interior side of the valve head engages and seats on the
spout peripheral curved surface 132.
[0135] The spout surfaces 130 and 132, which are part of the valve
restraint structure of the discharge conduit or spout 36, prevent
the valve head 150 from deflecting further inwardly into the spout
36. This prevents in-venting of ambient atmosphere through the
valve 38 into the spout and pump whenever the ambient exterior
atmospheric pressure exceeds the pressure within the spout 36. That
would be an undesirable occurrence because subsequent operation of
the pump to dispense the liquid would result in the discharge of a
reduced amount of liquid together with the in-vented air.
[0136] With respect to FIG. 16, it can be appreciated that the flow
paths 140 at the distal end of the spout 36 are arrayed laterally
outwardly at, or beyond, the peripheral edge of the head 150 of the
valve 38. Thus, virtually the entire interior surface of the valve
head 150 can be supported or restrained against in-venting forces
by the internal restraint structure in the spout 36.
[0137] When the liquid within the spout 36 is pressurized by the
pump during actuation of the pump, the pressurized liquid in the
flow passages 140 acts against the valve sleeve 154. When the
pressure differential across the valve sleeve 154 is sufficiently
great, the valve sleeve 154 is forced outwardly and carries the
valve head 150 outwardly off of its seated engagement with the
spout valve restraint surfaces 130 and 132. The liquid is then able
to move between the interior surface of the valve head 150 and the
spout valve restraint surfaces 130 and 132 so as to pressurize the
interior surface of the valve head 150. This results in a greater
total force on the interior surface of the valve 38, and the valve
moves to the outwardly extended, open, dispensing position shown in
FIG. 20.
[0138] FIG. 14 illustrates the novel, and advantageous profile
configuration of the valve flange 160. The valve flange 160 readily
accommodates proper assembly of the valve into the spout,
accommodates the inelastic deformation or swaging of the spout
retention wall 120 over the valve flange 160, and facilitates the
establishment of an effective attachment of the valve 38 to the
spout 36 in a way that provides enhanced resistance to valve
pull-out and in a way that provides enhanced leak-tight sealing
engagement between the valve flange 160 and the spout 36.
[0139] In the following discussion and in the claims, the surfaces
of the valve flange 160 are described with reference to the cross
section view taken radially through the valve 38 (FIGS. 14 and
16).
[0140] The flange 160 may be characterized as resilient material
extending from the periphery of the sleeve 154 in a generally
annular configuration about a longitudinal axis 172 (FIG. 14) that
extends axially inwardly and axially outwardly relative to the flow
direction of the fluid through the valve. The generally annular
configuration of the resilient material defining the valve flange
160 is located around, and radially outwardly of, the longitudinal
axis 172. The resilient material forming the flange 160 has a
surface region defined at least in part by the following
surfaces:
[0141] (A) a first surface 191 extending generally axially
outwardly from the sleeve 154;
[0142] (B) a second surface 192 extending generally axially
inwardly from the sleeve 154;
[0143] (C) a third surface 193 extending both generally axially
outwardly and radially outwardly from the first surface 191;
[0144] (D) a fourth surface 194 extending both generally axially
inwardly and radially outwardly from the second surface so that the
third and fourth surfaces generally diverge;
[0145] (E) a fifth surface 195 extending from the third surface 193
both generally axially inwardly and radially outwardly;
[0146] (F) a sixth surface 196 extending from said fourth surface
both generally axially outwardly and radially outwardly;
[0147] (G) a seventh surface or shoulder surface 197 extending
generally axially outwardly from the sixth surface 196;
[0148] (H) an eighth surface 198 extending generally axially
inwardly from the seventh surface 197;
[0149] (I) a ninth surface 199 extending generally axially
outwardly from the eighth surface 198; and
[0150] (J) a tenth surface or lip 210 extending generally radially
inwardly from the ninth surface 199.
[0151] The above-described configuration of the valve flange 160 is
particularly suitable for accommodating swaging of the spout
retention wall 120 (FIG. 12) by ultrasonic deformation into the
inelastically deformed, retaining configuration shown in FIGS. 1
and 16.
[0152] The ultrasonic swaging of the spout retention wall 120 may
be effected by substantially the same process as described above
for ultrasonically swaging the pump housing retention wall 70 about
the diaphragm flange 60. In a presently preferred process for
ultrasonically swaging the spout retention wall 120, the ultrasonic
horn applies a swaging force of about 1075 pounds to the wall 120.
However, it is to be realized that other swaging processes could be
employed, including non-ultrasonic swaging techniques.
[0153] In the presently most preferred process, the wall 120 is
swaged against the outlet valve flange 160 so as to compress the
flange 160 between about 0.000 inch and 0.004 inch, most preferably
about 0.004 inch.
[0154] After the components have been assembled as described above
to provide an operable pump 30, the pump 30 may be connected to a
supply of fluid, such as liquid soap, and then operated or actuated
to dispense the liquid. The pump 30 is especially well-suited for
incorporation into a dispenser 10 of the type illustrated and
described in the U.S. Pat. No. 6,216,916.
[0155] In any case, the pump 30 is actuated by pushing in on the
flexible dome 52, either directly, or indirectly through
intervening mechanical elements (such as the actuation lever 31
illustrated in the U.S. Pat. No. 6,216,916). The flexible,
resilient dome 52 is pushed inwardly with sufficient force so that
it pressurizes the liquid within the cavity and somewhat deforms or
collapses as illustrated in FIG. 19 herein.
[0156] The pressurization of the liquid within the cavity of the
dome 52 imposes a force on the inside surface of the diaphragm flap
56 over the inlet conduit seat 64. This establishes an even greater
fluid-tight engagement between the exterior surface of the flap 56
and the seat 64. The pressurized liquid within the cavity of the
dome 52 is then forced out through the outlet flow passage in the
boss 44, into the outlet discharge structure or spout 36, and
against the sleeve 154 of the outlet valve 38. This causes the
outlet valve 38 to open as illustrated in FIG. 19.
[0157] When the user terminates the pushing force on the resilient
dome 52, the dome 52 returns to its original, unstressed, outwardly
convex configuration. This increases the volume of the cavity under
the dome 52 so as to reduce the pressure within the cavity. The
reduced pressure in the dome cavity forces the diaphragm flap 56
away from the seat 64 (as shown in FIG. 21). Liquid is typically
always present in the inlet conduit 42 so that the liquid in the
inlet conduit 42 can then flow past the open inlet flap 56 into the
cavity in the diaphragm dome 52 and into the other discharge
passages in the pump that communicate with the cavity. The outlet
valve head 150 cannot open inwardly under the influence of reduced
pressure in the diaphragm cavity because of the restraint structure
surfaces 130 and 132 (FIG. 16). The restraint structure can also
minimize the effects of hydraulic water hammer pressure on the
outlet valve 38 when the diaphragm dome 52 is subjected to a high,
rapidly applied actuating force.
[0158] When the pushing force has been released from the diaphragm
dome 52, the pressure of the fluid in the discharge spout 36
returns to the substantially ambient atmospheric pressure (or
slightly higher owing to the liquid static head in the pump). Then,
owing to the inherent resiliency of the outlet valve 38, the outlet
valve 38 returns to its normal self-sealing, closed configuration
(FIGS. 1 and 14-16). In the preferred form of the outlet valve 38
illustrated, the valve 38 has sufficient resiliency to remain in
the self-sealed, closed configuration even with liquid remaining in
the pump above the valve because the static head pressure exerted
by such liquid on the closed valve 38 is not sufficient to open the
valve 38.
[0159] It will be readily apparent from the foregoing detailed
description of the invention and from the illustrations thereof
that numerous variations and modifications may be effected without
departing from the true spirit and scope of the novel concepts or
principles of this invention.
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